Study Guide
TMT-121131

©2011 Navistar, Inc.
4201 Winfield Road, Warrenville, IL 60555.
All rights reserved.
No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of
Navistar, Inc.

INTRODUCTION ................................................................1
MODULE 1: Hard-Start No-Start Required Test
Procedures .................................................................5
Section 1: Overview .............................................................5
Section 2: Initial Key On Check ........................................5
Section 3: Visual Inspection ..............................................6
Section 4: EST Connection and Data Recording ...........7
Section 5: Check For DTCs ................................................8
Section 6: Engine Cranking ...............................................9
Section 7: Relative Compression Test ...........................10
MODULE 2: Hard-Start No-Start Diagnostics
Special Test Procedures ........................................13
Section 1: Overview ...........................................................13
Section 2: Electrical Diagnostics: Inlet Air Heater
Amperage Draw ............................................................13
Section 3: Fuel Delivery Pressure Diagnostics ...........14
Part 1: Overview ..........................................................14
Part 2: Fuel Pump Electrical Check .........................14
Part 3: Aeration Check ...............................................15
Part 4: Fuel Filter Check ............................................16
Part 5: Alternative Fuel Supply Check ....................17
Section 4: Injection Control Pressure Diagnostics ....17
Part 1: Overview ..........................................................17
Part 2: ICP Open Loop Test .......................................18
Part 3: High-pressure Reservoir Inspection ..........18
Part 4: IPR Control Test .............................................19
Part 5: High-pressure Oil Pump Test .......................20
Part 6: IPR Block-off Test ..........................................20
Part 7: High-Pressure Oil Rail Leak Test ................21

MODULE 3: Performance Diagnostics .......................23
Section 1: Overview .......................................................... 23
Section 2: KOER Standard Test ..................................... 23
Section 3: Fuel Aeration Check ..................................... 24
Section 4: Engine Low Idle to High Idle ....................... 24
Section 5: Torque Converter Stall Test ......................... 26
Section 6: IPR Circuit Test .............................................. 26
Section 7: KOER Air Management Test ........................ 27
Section 8: TC2WC Operational Test .............................. 28
Section 9: TC2WC Solenoid Test ................................... 28
Section 10: Isolated Actuator Test ................................ 29
Section 11: Crankcase Oil Breather Separator Test .. 30
Section 12: Crankcase Pressure Test ........................... 30
Section 13: Relative Compression Test .........................31
Section 14: Cylinder Cut-Out Test ..................................31
Section 15: Road Test ...................................................... 32
CONCLUSION ..................................................................35

Introduction 1
Welcome to this engine-training course, 2010 MaxxForce ® DT, 9, and
10 Diagnostics for Technicians. This course will introduce technicians to the diagnostic procedures used to solve starting and performance problems.
This program consists of this introduction and the following three modules: Hard-Start No-Start Required
Tests Procedures, Hard-Start No-
Start Special Test Procedures, and Performance Diagnostic Test
Procedures.
Upon completion of this course, you will be able to identify the steps and procedures used to diagnose both starting and engine performance issues, and use ServiceMaxx™ to perform various engine tests.
This program refers to Engine
Symptoms Diagnostics, Hard-Start
No-Start Diagnostics, Performance
Diagnostics, Electronic Control
Systems Diagnostics, Performance
Specifications, and the Diagnostic
Trouble Code Index. Each of these refers to a section of the diagnostic manual on ISIS ® .
The diagnostic manual on ISIS ® includes both Hard-Start No-Start and
Performance Diagnostic procedures.
Objectives
Upon completion of this course, you will be able to:
• Identify the steps and procedures used to diagnose both starting and engine performance issues.
•Use ServiceMaxx™ to perform various engine tests.
“Each of these refers to a section of the diagnostic manual on ISIS ® .”

2 2010 MaxxForce ® DT, 9 and 10 Diagnostics
“There are several tests used to identify the cause of a starting issue.”
This module will cover the required tests used to diagnose starting issues.
The two forms available when diagnosing these engines are Hard-
Start No-Start Diagnostics and
Performance Diagnostics. Both forms are found on ISIS ® and can be used to avoid lost time and unnecessary repairs.
There are several tests used to identify the cause of a starting issue. These tests are divided into required tests and special system tests.
Always perform the required tests in sequence, and perform the special tests only when directed by the results of a required test.
If the cause of the problem is found when performing a required test, repair the fault and retest. If the problem was corrected, do not complete any remaining required tests. In addition, always use the latest service literature when servicing an engine.

Introduction 3
NOTES

4 2010 MaxxForce ® DT, 9 and 10 Diagnostics
NOTES

Module 1: Hard-Start No-Start Required Test Procedures
Overview
This module will explain the required tests for Hard-Start and No-Start issues.
There are six required tests for starting issues. They are:
• Key-On Check
• Visual Inspection
• EST and Data
• Check for DTC’s
• Engine Cranking
• Relative Compression
“This module will explain the required tests for
Hard-Start and
No-Start issues.”
Initial Key-ON Check
The first test is the Initial Key-ON
Check.
Start by turning the ignition switch ON.
Now, watch the instrument panel for a
Water-In-Fuel message. The message will flash for 5 to 10 seconds and turn off. If the message stays on solid after 5 to 10 seconds, take a fuel sample from the filter module and check for water.
“If the message stays on solid after
5 to 10 seconds, take a fuel sample from the filter module and check for water.”
5

6 2010 MaxxForce ® DT, 9 and 10 Diagnostics
Visual Inspection
The second Required Test procedure is the Visual Inspection of the engine.
“Low oil level or low oil pressure can affect the oil level in the highpressure reservoir and prevent the injectors from operating.”
Start by checking the oil level and quality. If the oil level is low, inspect for leaks.
Low oil level or low oil pressure can affect the oil level in the high-pressure reservoir and prevent the injectors from operating.
Ensure the oil is the proper viscosity and not contaminated with fuel or coolant. Contaminated oil will also prevent the injectors from operating correctly.
Inspect the fuel system. Check the fuel level in the tank and inspect the system for leaks.
Take a fuel sample from the filter module and check for water, sediment, gasoline, kerosene, waxing, and icing. If necessary, take a sample from the tank to determine if the fuel in the tank is contaminated.
Check the coolant level in the deaeration tank. A low coolant level could indicate other engine problems. Also, check if the coolant is contaminated with oil. Oil in the coolant may be an indication of major engine failure.

Module 1: Hard-Start No-Start Required Test Procedures
Check the exhaust system. Leaks around the Exhaust Aftertreatment
Assembly or dented pipes could be a sign of a high restriction that could prevent the engine from starting.
Check the air-filter restriction-indicator.
If the restriction is greater than 25 inches of water, or 6.2 kPa, replace the air filter and retest.
Inspect the charge-air system for leaks.
Leaks in the charge-air piping will allow dirt and dust to enter the system.
Check the Electrical System for chaffed wiring or broken connections.
Inspect the camshaft position sensor, crankshaft position sensor, and the injection pressure regulator for proper electrical connection. When these components are disconnected, the engine will not start.
EST Connection and Data
Recording
The third Required test procedure is
EST Connection and Data Recording.
Start by establishing communication between the Electronic Service Tool, or
EST, and the ECM.
If communication cannot be established, refer to “J1939 Data
Link” in “Electronic Control System
Diagnostics.”
“Leaks around the Exhaust
Aftertreatment
Assembly or dented pipes could be a sign of a high restriction that could prevent the engine from starting.”
7

8 2010 MaxxForce ® DT, 9 and 10 Diagnostics
Now check for biased sensors by recording their Key-On Engine Off values.
“Monitor the sensor values and record them on the diagnostic form.”
Monitor the sensor values and record them on the diagnostic form.
Compare these sensor values to specifications. Diagnose sensors that are out of spec by referring to “Electronic Control Systems
Diagnostics.”
Next, run the high and low output state test and monitor the EGR Control and
Engine Throttle Position values. If either value does not meet specifications, refer to Electronic Control Systems
Diagnostics.
Finally, record the status of the Diesel
Particulate Filter on the diagnostic form.
Checking for DTCs
The fourth required test Procedure is to
Check for DTCs.
“Start by checking the engine for active and previously active diagnostic trouble codes.”
Start by checking the engine for active and previously active diagnostic trouble codes.
2010 engines now use Suspect
Parameter Number, or SPN, and a
Failure Mode Indicator, or FMI to identify failure codes.
Refer to the “Diagnostic Trouble
Code Index” to diagnose any active

Module 1: Hard-Start No-Start Required Test Procedures codes before continuing. Evaluate any previously active DTCs that would have an effect on starting.
Engine Cranking
The fifth required test procedure is
Engine Cranking. This test allows you to analyze the engine’s systems by monitoring specific sensor values while cranking.
Start by using an appropriate adapter to connect the fuel pressure gauge to the intake manifold.
Open the hard-start no-start session in ServiceMaxx™. Then, press the record button and crank the engine for a maximum of 10 seconds while monitoring the fuel pressure gauge.
After cranking the engine, look at the following values in the recorded snapshot: Switch Battery, Engine
Speed, Injection Control Pressure, and
Exhaust Back Pressure.
If Switch Battery drops below specification, see “ECM Power” in “Electronic Control Systems
Diagnostics.”
If the engine speed remains at 0 RPM, see “CKP and CMP” in “Electronic
Control Systems Diagnostics.”
“The Engine
Cranking test allows you to analyze the engine’s systems by monitoring specific sensor values while cranking.”
9

10 2010 MaxxForce ® DT, 9 and 10 Diagnostics
“If engine-cranking speed is below spec, check the starting and charging systems.”
If engine-cranking speed is below spec, check the starting and charging systems.
If fuel delivery pressure is below specification, refer to the fuel system special test procedures.
If injection control pressure is below specification, perform the ICP Open
Loop test in Special Test Procedures.
If EBP is above spec, check the position of the exhaust brake valve. The valve should be open while cranking the engine. If the valve is open, drop the exhaust before the Pre-DOC and monitor EBP during cranking. If the
EBP is now within spec, check the exhaust system for restrictions.
“The Relative
Compression
Test is used to determine if each cylinder is in good mechanical condition.”
Relative Compression Test
The sixth required test procedure is the
Relative Compression Test. This test is used to determine if each cylinder is in good mechanical condition.
During this test, the ECM looks at the speed of each piston’s approach to top-dead-center compression and then the speed of each piston’s down-stroke after passing top-dead-center. The
ECM compares the two speeds and calculates the difference.
Start by opening the Relative
Compression Test in ServiceMaxx™.

Module 1: Hard-Start No-Start Required Test Procedures 11
A window will appear to guide you through the test procedure.
The test will begin and you’ll be instructed to crank the engine. After several seconds, the on-screen instructions will tell you to stop cranking. ServiceMaxx™ will now gather the information from the test and tell you to review the results.
A graph of the results will appear once the test is complete. A cylinder with low compression is represented by a shorter bar on the graph. In this case, the speeds of the piston’s approach and down-stroke have little difference.
Repeat this test a total of three times and compare the results from each test.
This concludes the Hard-Start No-Start
Required Test Procedures.
“A cylinder with low compression is represented by a shorter bar on the graph.”

12 2010 MaxxForce ® DT, 9 and 10 Diagnostics
NOTES

Module 2: Hard-Start No-Start Diagnostics Special Test Procedures 13
Overview
This module explains the special test procedures for electrical diagnostics, fuel delivery diagnostics, and injectioncontrol-pressure diagnostics.
Only perform these special procedures if directed by one of the six required tests.
Electrical Diagnostics: Inlet
Air Heater Amperage Draw
This section covers the amperage draw test used when diagnosing the Inlet Air
Heater.
Start by installing an amp clamp around the Inlet Air Heater relay battery positive circuit.
Turn the ignition switch ON.
Now, use ServiceMaxx™ to perform the
Intake Air Heater Test.
Observe the meter reading and record this information on the diagnostic form.
If the amperage draw does not meet specifications, refer to the Inlet Air
Heater System in “Electronic Control
System Diagnostics.”
“Start by installing an amp clamp around the Inlet
Air Heater relay battery positive circuit.”

14 2010 MaxxForce ® DT, 9 and 10 Diagnostics
If the amperage draw meets specifications, the Inlet Air Heater is working correctly.
Fuel Delivery Pressure
Diagnostics
Overview
This section covers the four tests used when diagnosing the Fuel Delivery
System. These four tests will check for a faulty fuel pump, fuel aeration, high fuel inlet restriction, and a clogged filter.
“The Fuel Pump
Electrical Check verifies that the fuel pump is receiving the correct voltage.”
Fuel Pump Electrical Check
The first test is the Fuel Pump Electrical
Check. This test verifies that the fuel pump is receiving the correct voltage.
Start by connecting Breakout Harness
6023 between the engine harness and the fuel pump. Turn the ignition switch
ON. Measure the voltage between pins
1 and 4, then between 1 and 6. Record the measurement.
The fuel pump times out after 10 seconds unless engine speed is present. Wait 10 seconds between ignition switch cycles to reset the timer.
If the voltage does not fall between
9-12 volts, go to FPC in “Electronic
Control System Diagnostics.”

Module 2: Hard-Start No-Start Diagnostics Special Test Procedures 15
Aeration Check
The second test is the Aeration Test.
This test will determine the cause of fuel aeration.
Start by connecting the Fuel Pressure
Gauge to the test port on the front of the intake manifold. Route the end of the clear hose into a diesel fuel container.
Now turn the ignition switch ON.
While the pump is running, open the gauge shut-off valve briefly to check for aeration.
If the fuel is not aerated, continue to the
Fuel Filter Test.
If the fuel is aerated, continue to the next step.
Use the appropriate adapter to connect the clean fuel tank to the fuel filterhousing inlet, and then connect a fuel pressure gauge to the front of the intake manifold.
Now, turn the ignition switch ON. Open the shut-off valve to check for aeration.
If the fuel is still aerated with the clean fuel tank attached, replace the fuel filter housing.
If the fuel is not aerated, inspect and repair the fuel tank and lines as necessary.
“Use the appropriate adapter to connect the clean fuel tank to the fuel filterhousing inlet.”

16 2010 MaxxForce ® DT, 9 and 10 Diagnostics
Fuel Filter Check
The third test is the Fuel Filter Check.
This test allows you to determine if the fuel filter is restricted.
Connect the Fuel/Oil Pressure Test
Coupler and the Fuel Pressure Gauge to the filter housing test port.
“If the fuel pressure was below spec at the intake manifold test port, and is now within spec at the fuel filter housing test port, the filter is restricted.”
Turn the ignition switch ON. Record the gauge reading.
If the fuel pressure was below spec at the intake manifold test port, and is now within spec at the fuel filter housing test port, the filter is restricted. Replace the filter and clean the strainer.
If the pressure is below specification at both test ports, the fuel pressure regulator may be the cause. To check this, disconnect the fuel return line from the Fuel Filter housing. With the return line disconnected, the check valve in the return fitting closes and deadheads the system. Turn the ignition switch On, and measure the fuel pressure.
If fuel pressure is now above specification, replace the Fuel Pressure
Regulator.
If fuel pressure is still below specification, go to the Alternative Fuel
Supply Test.

Module 2: Hard-Start No-Start Diagnostics Special Test Procedures 17
Alternative Fuel Supply Test
The fourth test is the Alternative Fuel
Supply test. This test is used to verify that the fuel supply is not restricted.
Connect the fuel pressure gauge to the filter housing test port. Use the appropriate adapter to connect the clean fuel tank to the filter-housing inlet.
Turn the ignition switch ON. Measure and record the fuel pressure.
If the fuel pressure is now within specification, the system was restricted.
Inspect and repair the fuel tank and lines as necessary.
If fuel pressure is still below specification, replace the fuel pump.
“The Alternative
Fuel Supply test is used to verify that the fuel supply is not restricted.”
“If fuel pressure is still below specification, replace the fuel pump.”
Injection Control Pressure
Diagnostics
Overview
This section covers the six tests used when diagnosing the Injection Control
Pressure, or ICP System. These six tests will check for a Biased ICP
Sensor, empty reservoir, Injection pressure regulator circuit faults, failed high-pressure oil pump, failed Injection
Pressure Regulator valve, and under valve cover leaks.

18 2010 MaxxForce ® DT, 9 and 10 Diagnostics
“The ICP Open
Loop Test chaecks for a biased ICP sensor or circuit.”
ICP Open Loop Test
The first test is the ICP Open Loop test. This test checks for a biased ICP sensor or circuit.
Start by disconnect the gray Under
Valve Cover connector, or UVC 1, and then crank the engine for a maximum of 20 seconds. This test will set an ICP code. Ignore the code and clear it after
UVC 1 is reconnected.
If the engine starts, see ICP Sensor in “Electronic Control System
Diagnostics.”
If the engine does not start, perform the High-Pressure Pump Reservoir
Inspection.
“The High-Pressure
Pump Reservoir
Inspection checks the level of the oil in the highpressure pump reservoir.”
High-Pressure Pump Reservoir
Inspection
The second test is the High-Pressure
Pump Reservoir Inspection. This test checks the level of the oil in the highpressure pump reservoir.
Loosen the Engine Oil Temperature sensor. Watch for oil leaking around the sensor’s threads.
If oil does not leak from around the threads, the reservoir is empty.
See Lubrication System in “Engine
Symptoms Diagnostics.”

Module 2: Hard-Start No-Start Diagnostics Special Test Procedures 19
If the reservoir is full, perform the IPR
Control Test.
IPR Control Test
The third test is the IPR Control Test.
This test checks the Injection Pressure
Regulator, or IPR, circuit.
Start by disconnecting the IPR connector and inspect it for damage or corrosion. Fix the connection if necessary.
Next, connect breakout harness ZTSE-
4484 to the IPR valve, and leave the engine harness disconnected.
Now, energize the IPR valve by connecting battery positive and ground to the breakout harness.
Use ServiceMaxx™ to monitor ICP while cranking the engine.
If the ICP builds above 28 MPa, or
4000 psi, refer to IPR in “Electronic
Control System Diagnostics.”
If the ICP does not build to 28 MPa, or
4000 psi, perform the High-Pressure
Oil Pump Test.
!
Caution
Do not connect the test harness directly to the engine harness.
Doing so will result in a blown fuse.

20 2010 MaxxForce ® DT, 9 and 10 Diagnostics note
This test retains
Breakout Harness
ZTSE-4484 with
B+ and ground connections from the
IPR Control test. note
This test retains the mechanical gauge from the High-
Pressure Oil Pump
Test.
High-Pressure Oil Pump Test
The fourth test is High-Pressure Oil
Pump Test. This test determines if the high-pressure oil-pump can provide maximum ICP.
Start by removing the high-pressure hose from the cylinder head fitting.
Install the Mechanical Gauge to the high-pressure hose. Now monitor the gauge while cranking the engine.
If ICP goes above 28 MPa, or 4000 psi, perform the High-Pressure Rail
Leak Test.
If ICP does not go above 28 MPa, or
4000 psi, perform the IPR Block-Off
Test.
IPR Block-Off Test
The fifth test is the IPR Block-off Test.
This test determines which of the following has failed: the high-pressure pump or the IPR valve.
Start by removing the IPR valve from the high-pressure oil pump. Install the IPR Plug Tester. Now monitor the gauge while cranking the engine.
If ICP goes above 28 MPa, or 4000 psi, replace the IPR valve.
If ICP does not go above 28 MPa, or
4000 psi, replace the high-pressure pump.

Module 2: Hard-Start No-Start Diagnostics Special Test Procedures 21
High-Pressure Oil Rail Leak Test
The sixth test is the High-Pressure Oil
Rail Leak Test. This test locates the cause of oil leaks under the valve cover.
Start by reconnecting the high-pressure hose. Remove the valve cover and disconnect the injector connectors.
Connect the breakout harness ZTSE-
4484 to the IPR valve. Next, energize the IPR valve by connecting battery positive and ground to the breakout harness.
Now, inspect the high-pressure oil rail for leaks while cranking the engine.
If oil is leaking from the Engine
Compression Brake valve, replace the valve.
If oil is leaking from the o-ring between the cylinder head and rail, remove the rail and replace the O-ring.
If any of the oil inlet adapters are leaking excessively, remove the rail and replace the failed inlet adapter.
If the ICP sensor is leaking, replace the sensor and o-ring.
This concludes the Hard-Start No-Start
Special Test Procedures.
note
Perform this test only if directed here from the High-pressure Oil
Pump Test.

22 2010 MaxxForce ® DT, 9 and 10 Diagnostics
NOTES

Overview
This module explains the test procedures for diagnosing a performance issue.
The 18 tests in Performance diagnostics are shown here. Five of those are identical to tests covered in
Hard-Start No-Start required tests.
In this module, we will only cover the thirteen tests that are unique to
Performance Diagnostics.
KOER Standard Test
Tests one through four, Initial Key-
On Check, Visual Inspection, EST
Connection and Data Recording, and
Checking for DTCs were covered in
Hard-Start No-Start required tests.
The fifth test is the Key On Engine
Running Standard Test. This test checks the ability of the ICP system to create the proper pressure.
Start by selecting the KOER Standard
Test in ServiceMaxx™.
The ECM controls the engine speed while commanding maximum ICP pressure. The Test then returns the engine to idle and lowers ICP to the normal pressure.
Module 3: Performance Diagnostics 23
“This module explains the test procedures for diagnosing a performance issue.”
“The KOER
Standard Test checks the ability of the ICP system to create the proper pressure.”

24 2010 MaxxForce ® DT, 9 and 10 Diagnostics
If a code sets during the test, go to
“Diagnostic Trouble Code Index.”
“The Fuel Aeration
Check checks for aerated fuel.”
Fuel Aeration Check
The sixth test is the Fuel Aeration
Check. This test checks for aerated fuel.
Start by connecting the Fuel Pressure
Gauge to the intake manifold test port.
Route the clear hose of the gauge into a clean fuel container.
Now, turn the ignition switch ON and open the gauge shut-off valve. Watch the clear hose to check for aeration.
If the fuel is aerated, perform the fuel delivery system procedures in Hard-
Start No-Start Special Tests.
If the fuel is not aerated, perform the engine low idle to high idle test.
“The Engine
Low Idle to
High Idle Test monitors engine performance throughout the
RPM range.”
Engine Low Idle to High Idle
Test
The seventh test is the Engine Low Idle to High Idle Test. This test monitors engine performance throughout the
RPM range.
Start by selecting the Performance
Session in ServiceMaxx™. Press the record button and wait five seconds.
Now, monitor the Accelerator Pedal
Position signal, as you press the

Module 3: Performance Diagnostics 25 accelerator pedal fully to the floor. If the signal does not go from 0% to 99.6% see APP in the “Electronic Control
Systems Diagnostics.”
Next, start the engine and idle for 20 seconds. Then press the accelerator pedal completely to the floor for 20 seconds. Now, return to low idle.
Open the snapshot file and compare
Fuel Delivery Pressure, Injection
Control Pressure, Exhaust Back
Pressure, Diesel Particulate filter differential pressure, and Intake
Manifold Pressure to both high idle and low idle specifications.
If Fuel Delivery pressure is out of spec, see fuel system in Hard-Start No-Start
Diagnostics.
If the engine does not accelerate smoothly or feels like it is misfiring, perform the relative compression and cylinder cut out tests.
If ICP is below spec, perform the
ICP tests in Hard-Start No-Start
Diagnostics.
If EBP is above specification, inspect for turbocharger damage.
If the Diesel Particulate Filter Differential
Pressure is above spec, refer to the
Aftertreatment system in “Electronic
Control System Diagnostics.”
“If Fuel Delivery pressure is out of spec, see fuel system in Hard-
Start No-Start
Diagnostics.”

26 2010 MaxxForce ® DT, 9 and 10 Diagnostics
If Intake Manifold Pressure is below spec, check the charge air cooling system for leaks and perform the crankcase pressure test.
If the values are within spec, continue to the Torque converter stall test.
“The Torque
Converter Stall
Test checks engine performance under load when equipped with an automatic transmission.”
Torque Converter Stall Test
The eighth test is the Torque
Converter Stall Test. This test checks engine performance under load when equipped with an automatic transmission.
Start by setting the parking brake and apply the service brakes. Then open the Performance Session in
ServiceMaxx™.
Start the engine and shift to drive.
Press the record button. Wait five seconds and push the accelerator firmly to the floor. Record the number of seconds it takes to reach the stall RPM.
If the stall test results are within spec, there are no performance issues.
If the stall test results are out of spec, proceed to the IPR Circuit Test.
IPR Circuit Test
The ninth test is the IPR Circuit Test.
This test determines if the Injection
Control Pressure system is producing stable pressure.

Module 3: Performance Diagnostics 27
Begin by opening the Performance
Session and starting the engine.
Wiggle the IPR connector while monitoring the ICP signal. If the engine stumbles, check the IPR connector and repair as necessary.
Next, press the accelerator pedal to the floor and hold for 30 seconds. If the injection control pressure surges more than 1000 psi, stop the engine and disconnect UVC 1. Restart the engine and run the test again.
If the surge is still present, replace the
IPR valve.
If the surge is not present, replace the
ICP sensor.
KOER Air Management Test
The tenth test is the Key On Engine
Running Air Management Test. This test checks the operation of the EGR system.
Begin by Starting the engine and selecting the Air Management Test.
During this test, the ECM raises engine speed and measures mass airflow.
With the airflow calculated, the ECM commands the EGR valve open, and looks for a change in mass airflow.
If a DTC sets during the test, refer to the “Diagnostic Trouble Code Index.”
“If the engine stumbles, check the IPR connector and repair as necessary.”
“The Key On
Engine Running
Air Management
Test checks the operation of the
EGR system.”

28 2010 MaxxForce ® DT, 9 and 10 Diagnostics
“The Turbocharger
2 Wastegate
Control Operational test verifies that the turbocharger wastegate is operating properly.”
Turbocharger 2 Wastegate
Control Operational Test
The eleventh test is the Turbocharger
2 Wastegate Control Operational test.
This test verifies that the turbocharger wastegate is operating properly.
Begin by turning the pressure regulator knob of special tool ZTSE-4409 counterclockwise to the lowest setting.
Connect shop air to the pressure regulator.
Next, use the proper hose and adapter to connect the regulated air source to the solenoid supply hose at the engine throttle valve.
Now, set the regulator to apply 21.5 psi, or 148.2 kPa, to the supply hose.
If the actuator rod moves smoothly through its range, perform the
Turbocharger Wastegate 2 Control
Solenoid Test.
If the rod doesn’t move, or if it sticks, then perform the Isolated Actuator Test.
Turbocharger 2 Wastegate
Control Solenoid Test
The twelfth test is the Turbocharger
2 Wastegate Control Solenoid Test.
This test determines if the solenoid is working correctly.

Module 3: Performance Diagnostics 29
Begin with the set-up from the operational-test and 21.5 psi or 148.2 kPa applied to the supply hose. Using
ServiceMaxx™, run the KOEO Output
State Tests High and Low.
If the actuator does not move, refer to
TC2WC in “Electronic Control Systems
Diagnostics.”
If the actuator cycles open and closed, the turbo control is working correctly.
Isolated Actuator Test
The 13th test is the Isolated Actuator
Test. This test checks the operation of the wastegate actuator.
Begin by applying 21.5 psi or 148.2 kPa directly to the wastegate actuator.
If the actuator rod moves smoothly through its range, but did not during the operational test, check for a leak or blockage in the hose or solenoid.
If the actuator rod does not move, remove the rod from the turbocharger wastegate arm. Check if the wastegate valve moves freely.
If the valve moves freely, replace the actuator.
If the valve does not move freely, replace the turbocharger.
note
When checking wastegate movement, mark the inner nut so the wastegate lever can be reinstalled in the same position.

30 2010 MaxxForce ® DT, 9 and 10 Diagnostics
“The Oil Breather
Separator Test determines if the separator is functioning correctly.”
Oil Breather Separator Test
The 14th test is the Oil Breather
Separator Test. This test determines if the separator is functioning correctly.
Start the engine and place a stethoscope on the Separator housing.
Shut the engine off and quickly monitor for rotational noise.
If no noise is heard, replace the centrifugal breather.
If noise is heard, the breather is functioning correctly.
“The Crankcase
Pressure Test determines if the engine has excessive crankcase pressure.”
Crankcase Pressure Test
The 15th test is the Crankcase
Pressure Test. This test determines if the engine has excessive crankcase pressure.
Begin the test by disconnecting the breather outlet tube at the oil separator.
Use a bolt to block the tube going to the turbo inlet duct.
Connect special tool ZTSE-4039 to the oil separator elbow and connect the tool to a monometer.
Next, start the engine and hold the accelerator to the floor. Wait until the monometer reading stabilizes. Now, record the pressure.

Module 3: Performance Diagnostics 31
If the pressure is above spec, refer to
Performance Diagnostics for further steps.
If the pressure is within spec, perform the relative compression test.
Relative Compression Test
The 16th test is the Relative
Compression Test. This test was covered earlier in the Hard-Start No-
Start Required Test Procedures.
Cylinder Cut Out Test
The 17th test is the Cylinder Cut
Out Test. This procedure pinpoints an inactive cylinder by disabling one injector at a time.
Start by opening the Cylinder Cutout test session and start the engine. Allow the engine to idle for five seconds.
Now, disable an injector. Monitor the engine load and fuel rate while listening for engine tone changes. Repeat this process for each injector.
Compare the results for a disabled injector to the baseline values for engine fuel rate and engine load. If the engine load and fuel rate did not increase when an injector was disabled, that cylinder is not contributing to engine performance.
“The Cylinder Cut
Out Test pinpoints an inactive cylinder by disabling one injector at a time.”

32 2010 MaxxForce ® DT, 9 and 10 Diagnostics
If the engine load and fuel rate did increase when an injector was disabled, that cylinder is contributing to engine performance. No action is required.
“The Road Test checks the engine’s performance at full load and rated speed.”
Road Test
The last test is the Road Test. This procedure checks the engine’s performance at full load and rated speed.
Start by turning the ignition switch ON and load the Performance session.
Now, start the engine and drive to an open stretch of road. When conditions are safe, start recording.
Select a suitable gear, and press the accelerator pedal fully to the floor and accelerate to rated speed at 100% load.
“When the road test is complete, stop recording and review the results.”
When the road test is complete, stop recording and review the results.
If Fuel Delivery pressure is out of spec, see fuel system in Hard-Start No-Start diagnostics.
If the engine does not accelerate smoothly or feels like it is misfiring, perform the relative compression and cylinder cut out tests.
If ICP is below spec, perform the
ICP tests in Hard-Start No-Start
Diagnostics.

Module 3: Performance Diagnostics 33
If EBP is above specification, inspect for turbocharger damage.
If Intake Manifold Pressure is below spec, check the charge air cooling system for leaks and perform the crankcase pressure test.
If the values are within spec, there is no performance issue.
“If the values are within spec, there is no performance issue.”

34 2010 MaxxForce ® DT, 9 and 10 Diagnostics
NOTES

This concludes the 2010 MaxxForce ®
DT, 9, and 10 Engine Diagnostics training program.
Thanks for your participation.
You are now required to take a posttest.
Conclusion 35

36 2010 MaxxForce ® DT, 9 and 10 Diagnostics
NOTES